IPCB001 Rev 6; CRN: 8934
IPC Integrated
Protection Relay
ANZ Ex 08.4071X
1. Description
The Ampcontrol IPC Integrated Protection Relay is an intelligent
protection relay based on microprocessor technology.
The integrated relay provides the necessary functions required
for protecting electrical outlets supplying mobile machines
powered by reeling or trailing cables. All of the protection
functions are combined into a compact, plug-in unit, which can
be easily changed out to minimise down time in the event of a
problem with the relay.
The IPC Relay can provide machine communication through
the use of a Remote Termination Unit (RTU) connected
between the pilot and earth at the machine end of the trailing
cable. Through the use of the RTU Remote Termination Unit
the relay parameters are automatically up loaded from a remote
machine when a cable is inserted into a power outlet.
The earth fault lockout function tests the resistance of the 3
phase lines to earth by applying an intrinsically safe signal prior
to the closure of the main contactor in accordance with
AS2081.4 1988. The test is initiated once all starting conditions
are met. If the resistance is above the preset level then an
automatic high voltage DC “Insulation Test” to earth of the cable
can be carried out. If the result of the Insulation Test is above
the preset resistance level, the IPC’s MCR relay energises,
which in turn closes the main contactor. A manual “Insulation
Test” is provided as a maintenance/fault finding tool. (When this
test is performed the MCR relay does not close at completion of
a healthy test).
The Insulation Test allows cable insulation levels to be trended
as an aid to preventative maintenance.
The IPC Relay has 5 Digital inputs, which feed into a
microprocessor unit. The microprocessor has been
programmed to control three output relays. Relay MCR for the
main contactor and Relay CBR for the circuit breaker. Relay
RL3 can be turned off or configured to follow the Fan Interlock
Drive output of the IPC Relay. All of the tripping logic and outlet
control is performed by the microprocessor, so that virtually no
external control is required.
Extensive information display and monitoring features are
included to facilitate fault finding and system trending. This
information can be read locally on the IPC Remote Display
Module (RDM-1K) or remotely via a communication link.
Opto-Isolated Outputs are available for connection to optional
LED or Relay Modules to provide additional “run and trip”
indications. The Ampcontrol Relay Output Module (ROU)
enables these indications to be interfaced with a PLC.
See IPC User Manual 119051 for full details
2. Protection Functions
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Earth Leakage
Earth Fault Lockout
Earth Continuity
Over-current /Overload
Short Circuit
Contactor Fail
3. Features
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Automatic and Manual High Voltage Insulation Test
Machine Communications
User friendly. Relay and Remote Termination Unit
programmed from the Remote Display Module
28 Status messages to indicate what is required to
energise the outlet.
Microprocessor based
Fail safe operation
Diode or Remote Termination Unit operation
IS Remote Display Module - Ex (ia)
120 Event Log
Local or remote operation
Sequencing and remote communication via PLC link
Plug-in for quick change out
Fan Interlocking provided on any outlet
Thermal modelling
Fully functional for a period of two (2) seconds during
extreme control power dip or power loss.
Relay & Digital Input Status to aid fault finding
4. Application
Over-current / Overload Protection:
The IPC Integrated Protection Relay is Mines Department
Approved for use in mining operations. For the protection of
mining equipment in hazardous areas the relay is installed in
a flameproof enclosure with the Remote Display Module
being installed outside the enclosure. This is possible
because of its intrinsically safe design.
Current Range: 7.5 to 464 Amps (60 to 116 A in 4A
increments x multiplier)
Current Multiplier: 1/8, 1/4, 1/2, 1, 2, 4 times
Time Multiplier: 0.05, 0.075, 0.1, 0.15, 0.2, 0.3, 0.4, 0.5, 0.6,
0.7, 0.8, 1.0 time’s
Cooling Multiplier: 0.2, 0.3, 0.4, 0.5, 0.8, 1, 2, 5, 10, 20, 50
times
4.1 Sequence Control
Through machine communication, the identity of the machine
can be transferred via serial communications to a PLC. This
allows the PLC to arrange sequencing particularly in longwall
installations.
4.2 Fan Interlocking
A fan interlocking facility can be selected to prevent outlets
from being energised until a mine ventilation fan is
operational. This facility eliminates the need for dedicated
outlets, and has a built in delay to cope with generator
supply.
Current Balance:
Trip Settings: 5%, 10%, 20%, 50% and off
Short Circuit Protection:
Trip Setting:
Trip Time:
3 to 10 times in 0.5 increments
(times full load)
20, 40, 60, 80, 100, 120, 160mS
Back EMF Timer:
Trip Delay Settings: 2, 5, 10 and 20 Seconds
4.3 Remote Data Communications
The IPC Integrated Protection Relay has the facility for
connecting remote monitoring equipment. This can be in the
form of peripheral equipment such as PLC’s.
For PLC applications each integrated protection relay is
connected to a Serial Interface Module (IPSI), which has its
output multi-drop connected to a DNET-IP2 Protocol
Converter. The Protocol Converter provides the
communications link to a PLC (See User Manual 118626 for
further details).
The Ampcontrol DNET-IP2 Serial Communication System
transfers data and commands between the Host System and
the modules using RS232, RS422 and RS485 protocols.
Machine Numbers: Can be allocated from 1 to 40
5. Specifications
Auxiliary Supply Volts:
1 N/O 5A/190VAC 100VA max
1 C/O 5A/190VAC 100VA max
110vac  10% 10VA, 50Hz  2Hz
6. Equipment List
Earth Leakage Protection:
110050
110145
101182
101500
119055
101490
101491
101487
101503
101526
117139
119051
101500
101649
101650
101654
101272
101826
Trip setting 100-500mA in 50mA increments
Time Delay - Instantaneous (<80mS), 150mS - 470mS in
40mS increments
Earth Continuity Protection:
Reset if resistance is <45 ohms
Trip if resistance is > 45 ohms
Shunt Leakage Trip if <1500 ohms
Operating Time 80, 120, 160, 200, 300, 400, 500mS
Pilot cable parameters: C <0.3uF, L <10mH, L/R<600uH/Ω.
Earth Fault Lockout Protection:
IS Test
Lockout if resistance is:
415V < 4.15k ohms
1000V < 10k ohms
3.3kV < 33k ohms
Insulation Test
Lockout resistance is selectable at 0.1, 0.2, 0.5, 1, 2, 5, 10,
and 15 Meg Ohm
AMPCONTROL ELECTRONICS
Ampcontrol CSM Pty Ltd ABN 35 000 770 141
7 Billbrooke Close CAMERON PARK NSW 2285
Phone: (02) 4903 4800
Fax:
(02) 4903 4888
E-mail: electronics@ampcontrolgroup.com
Web site: ampcontrolgroup.com
Fan Current
Threshold Level: 32% to 96% in 8% increments (% of full
load current)
Under-voltage Protection:
Selectable from 20% to 80% in 10% increments
Trip Delay 800mS
Serial Communications:
For information on Protocol and hardware requirements see
DNET-IP2 Serial Communication System User Manual.
Relay Contacts: MCR, CBR, RL3, RL4
Integrated Protection Relay IPC1V04
Module RTUD 1V01 Remote Terminal Unit
IPC Base Plate
Module IPC Remote Display RDM-1K
Module CCMC-415V Cable Connection.
Module CCMC-1000V Cable Connection
Module CCMC-3.3kV Cable Connection
Module CCMA-110V Cable Connection
Module IPA/IPB Relay/LED Output
Fuse Holder IPB Pilot Protection
Fuse 3A/660V Pilot Protection (Box 10)
Manual User IPC1 V04
Module IPC RDM c/w KEYPAD
Toroid EL500/60/100T 500mA 60mm ID
Toroid EL500/85/100T 500mA 85mm ID
Toroid EL500/112/100T 500mA 112mm ID
Current TXF 100/1 45mmID OL1 T/S IPA/B
Module EFTM 415/1kV IPC Earth/Fault Test